Integrated actuator coil and decoder module for irrigation control

ABSTRACT

An integrated actuator coil and decoder module for use in decoder-based irrigation control systems, and related methods of manufacture and installation, are provided herein. In one implementation, an irrigation control device comprises a body, decoder circuitry located within the body, a coil located within the body and coupled to the decoder circuitry, the coil adapted to develop an electromagnetic flux sufficient to cause actuation of a device controlling irrigation equipment in response to signaling from the decoder circuitry. Also included is an electrical connection coupled to the decoder circuitry and adapted to couple to a control wire path of a decoder-based irrigation control system. The decoder circuitry and the coil are integrated into a single device.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to irrigation control devicesand more specifically to decoder-based irrigation control systemincluding decoder units for coupling to actuator coil-controlledirrigation equipment.

2. Discussion of the Related Art

In decoder-based irrigation control systems, an irrigation controllersends signaling along a wire path to which one or more decoder devicesare attached. Each decoder device monitors transmissions on the wirepath and decodes this signaling to determine when to cause irrigationdevices coupled thereto to be activated and deactivated. The decodermodule typically includes circuitry formed on a printed circuit boardlocated within a housing. Wiring from the decoder module housing must becoupled to the wiring of the wire path as well as coupled to one or moreactuator devices each controlling the opening and closing of anirrigation rotor or valve. In one form, the rotor or valve is operatedby a solenoid coil as is well known in the art. Likewise, duringinstallation, the operator must provide and electrically connect twoseparate devices, a decoder module and an actuator coil module, to eachother and to the control wire path. FIG. 1 illustrates a separatedecoder module 102 and a coil unit 104 that are conventionally coupledtogether. For example, as illustrated in FIG. 2, for a solenoidactivated rotor assembly 200, the coil module 104 is coupled (in part bya bracket 212 and retainer 214) to the parts of a selector valveassembly 202 (including a pressure regulator) attached to a casingassembly 204. The electrical wire inputs to the coil module 104 are thenconnected to the electrical wire outputs from the decoder module 102,while the electrical wire inputs to the decoder module 102 are coupledto the control wire path from the irrigation controller. Thus, a typicalinstallation requires the connection of six wires to install the decodermodule 102 and a coil module 104.

As is well known, in operation, a portion of a plunger (not shown) ofthe selector valve assembly 202 is disposed within the coil unit 104while another portion is seated against a solenoid plunge port (notshown) within the selector valve assembly 202 in a normally closedposition. In this position, high pressure water flow from a main watercontrol valve (not shown) located within a main control valve portion206 of the device is flowed up high pressure water line 208 into theselector valve assembly 202 and its regulator and is prevented fromfurther movement by the normally closed position of the plunger againstthe solenoid port in the selector valve assembly 202. This results in aback pressure that causes the main water control valve to close. Inresponse to signals from the decoder module 102, the coil module 104causes the actuation of the plunger to move it off of (or unseat from)the solenoid plunge port allowing the high pressure flow in the highpressure line 208 to flow through the selector valve assembly 202 (andits pressure regulator), which relieves the back pressure and allowswater to flow through the main control valve and to a pop-up sprinklerdevice, i.e., the main water control valve is opened. The pop-upsprinkler device is located within the casing assembly 204 and extendsupwardly due to the water pressure through a top portion of the casingassembly 204. The high pressure flow exits the selector valve assembly202 down through a discharge flow line 210 which terminates within thecasing assembly 204 at a location downstream of the main water controlvalve.

SUMMARY OF THE INVENTION

Several embodiments of the invention provide an integrated actuator coiland decoder module for use in decoder-based irrigation control systems.

In one embodiment, the invention can be characterized as an irrigationcontrol device comprising: a body; decoder circuitry located within thebody; a coil located within the body and coupled to the decodercircuitry, the coil adapted to develop an electromagnetic fluxsufficient to cause actuation of a device controlling irrigationequipment in response to signaling from the decoder circuitry; and anelectrical connection coupled to the decoder circuitry and adapted tocouple to a control wire path of a decoder-based irrigation controlsystem. The decoder circuitry and the coil are integrated into a singledevice.

In another embodiment, the invention can be characterized as a method ofmaking an irrigation control device comprising the steps of: providingdecoder circuitry; providing a coil unit containing a wire coil adaptedto develop an electromagnetic flux sufficient to cause actuation of adevice that causes opening and closing of an irrigation valve upon theapplication of an electrical current to the wire coil; coupling anoutput of the decoder circuitry to an input of the coil unit; insertingthe decoder circuitry into a housing such that an electrical connectionto the decoder circuitry can be made from outside of the housing;sealing the decoder circuitry within the housing; sealing at least aportion of the coil unit to the housing, whereby forming an integrateddevice having both the decoder circuitry and the coil unit.

In a further embodiment, the invention can be characterized as a methodof electrically connecting an irrigation control device to a decoderbased irrigation control system comprising the steps of: electricallycoupling a first control wire of the decoder based irrigation controlsystem to a first electrical connection of an integrated coil anddecoder module; and electrically coupling a second control wire of thedecoder based irrigation control system to a second electricalconnection of the integrated coil and decoder module.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects, features and advantages of severalembodiments of the present invention will be more apparent from thefollowing more particular description thereof, presented in conjunctionwith the following drawings.

FIG. 1 illustrates a separate sprinkler coil and decoder module forcontrolling irrigation equipment in a conventional decoder-basedirrigation control system.

FIG. 2 illustrates a conventional decoder and electric sprinklerapplication including a separate coil module and decoder module.

FIG. 3 illustrates an integrated coil and decoder module for use in adecoder-based irrigation control system in accordance with oneembodiment of the invention.

FIG. 4 illustrates a decoder and electric sprinkler applicationincluding an integrated coil and decoder module in accordance withseveral embodiments of the invention.

FIG. 5 illustrates decoder circuitry and a coil module of the integrateddevice of FIG. 3 shown without the decoder housing in accordance withone embodiment of the invention.

FIGS. 6A and 6B illustrate other views of the integrated coil anddecoder module of FIG. 3 in accordance with other embodiments of theinvention.

FIG. 7 illustrates the decoder housing of one embodiment of the deviceof FIG. 3.

FIG. 8 illustrates a coil housing of one embodiment of the device ofFIG. 3 with a partial cutaway showing a wire coil.

FIG. 9 is a diagram of a decoder-based irrigation control systemincluding multiple integrated coil and decoder modules according toseveral embodiments of the invention.

Corresponding reference characters indicate corresponding componentsthroughout the several views of the drawings. Skilled artisans willappreciate that elements in the figures are illustrated for simplicityand clarity and have not necessarily been drawn to scale. For example,the dimensions of some of the elements in the figures may be exaggeratedrelative to other elements to help to improve understanding of variousembodiments of the present invention. Also, common but well-understoodelements that are useful or necessary in a commercially feasibleembodiment are often not depicted in order to facilitate a lessobstructed view of these various embodiments of the present invention.

DETAILED DESCRIPTION

The following description is not to be taken in a limiting sense, but ismade merely for the purpose of describing the general principles ofexemplary embodiments. The scope of the invention should be determinedwith reference to the claims.

Referring first to FIG. 3, a perspective view is shown of an integratedcoil and decoder module 300 for use in a decoder-based irrigationcontrol system in accordance with one embodiment of the invention. Theintegrated coil and decoder module 300 includes a module body 302 (alsoreferred to simply as body 302) including a decoder housing 304 (alsoreferred to as a first housing) and a coil housing 306 (also referred toas a second housing, solenoid housing or coil unit). The module 300 alsoincludes electrical connector wires 308 and 310 (also referred to aselectrical connections 308 and 310) extending from the decoder housing304. The decoder housing 304 includes decoder circuitry (e.g., shown inFIG. 5) and the coil housing 306 includes a wire coil or solenoid (e.g.,shown in FIG. 8) formed within. Although the decoder housing 304 and thecoil housing 306 are separate functional components, they are integratedtogether to form a single integrated coil and decoder module 300.

Advantageously, since the module 300 is integrated into a single body302, an installer need only connect the two electrical connections 308and 310 to the control wire path of a decoder-based irrigation controlsystem. It is noted that any electrical connections between the decodercircuitry within the decoder housing 304 and the wire coil within thecoil housing 306 are already made and sealingly contained within thebody 302.

Referring next to FIG. 4, a perspective view is shown of a decoder andelectric sprinkler application including the integrated coil and decodermodule 300 of FIG. 3. In this embodiment, in a solenoid activated rotorassembly 400, the coil housing 306 (or solenoid housing) is coupled (inpart by the bracket 212 and the retainer 214) to the components of theselector valve assembly 202 attached to the casing assembly 204 (whichis typically buried underground or located within a valve box above orbelow ground). In the illustrated embodiment, the casing assembly 204contains a pop-up and rotary sprinkler device (not shown). Accordingly,an installation in accordance with this embodiment only involves theconnection of two wires (e.g., electrical connections 308 and 310) toinstall the decoder module 300, as opposed to six wires in the separateddecoder module and coil module as illustrated in FIG. 2. Thus, with thenew module according to several embodiments of the invention, the taskof installing a decoder module and coil unit is simplified since thereare fewer wires to connect. Additionally, this embodiment provides aspace-saving design that is more streamlined and easier to install withless clutter due to excess wires. Furthermore, the installer only needsto provide and install a single integrated device rather than purchasingand providing a separate decoder module and a separate coil housingmodule.

In operation, a portion of a plunger (not shown) of the selector valveassembly 202 is disposed within a core tube (not shown) that extendsinto the opening of the coil housing 306 about which the coil is woundwhile another portion of the plunger is seated against a solenoid plungeport (not shown) within the selector valve assembly 202 in a normallyclosed position (e.g., a spring within the core tube holds the plungeragainst the solenoid plunge port). In this position, high pressure waterflow from a main water control valve (not shown) located within a maincontrol valve portion 206 of the device is flowed up high pressure waterline 208 into the selector valve assembly 202 and its regulator and isprevented from further movement by the normally closed position of theplunger against the solenoid port in the selector valve assembly 202.This results in a back pressure that causes the main water control valveto close. In response to signals from the decoder housing 304 portion ofthe integrated coil and decoder module 300, the coil module 306generates a magnetic field that causes the actuation of the plungerwithin the core tube to move it off of (or unseat from) the solenoidplunge port allowing the high pressure flow in the high pressure line208 to flow through the selector valve assembly 202 (and its pressureregulator), which relieves the back pressure and allows water to flowthrough the main control valve and to a pop-up sprinkler device, i.e.,the main water control valve is opened. The high pressure flow exits theselector valve assembly 202 down through a discharge flow line 210 whichterminates within the casing assembly 204 at a location downstream ofthe main water control valve. It is noted that the core tube extendsthrough the bracket 212 and the opening of the coil module 306 such thata portion extends through the back opening of the coil module 306 andback side of the bracket 212. The retainer 214 is preferably a rubberend cap that is positioned over the portion of the core tube extendingtherethrough to hold the coil module 306 in position against the bracket212 and the selector valve assembly 202.

Referring next to FIG. 5, a view shown of the decoder circuitry and coilmodule of the integrated device of FIG. 3 without the decoder housing inaccordance with one embodiment of the invention. Illustrated is aprinted circuit board 502 including decoder circuitry 504 formed on orotherwise coupled to or attached to the printed circuit board 502. Alsoillustrated are the electrical connections 308 and 310 coupled to thedecoder circuitry 504 for connection to the control wire path of thedecoder-based irrigation control system, as well as electricalconnections 506 and 508 extending from the decoder circuitry 504 intothe coil housing 306 to electrically couple the decoder circuitry 504 tothe wire coil of the coil housing 306. It is noted that the decodercircuitry 504, as well as the coil housing 306 including the coil formedwithin, are well-known in the art. For example, in one embodiment, thedecoder circuitry 504 is found within commercial decoder modulesavailable from the Rain Bird Corp., Glendora, Calif., for example, asingle channel, single coil decoder (part number FD-101). Likewise, inone embodiment, the coil housing 306 is commercially available from theRain Bird Corp., Glendora, Calif., as rotor coil, part number 212165.

In accordance with one embodiment, a commercially available coilhousing, such as coil housing 306, is electrically coupled tocommercially available decoder circuitry, such as decoder circuitry 504,via electrical connections 506 and 508. Such decoder circuitry includeselectrical input connections, such as electrical connections 308 and 310to be coupled to the control wire path of a decoder-based irrigationcontrol system. The decoder circuitry 504 and coil housing 306 are theninserted into a volume (see volume 706 of FIG. 7) formed within ahousing, such as the decoder housing 304, such that the electricalconnections 308 and 310 extend through at least one opening formed inthe decoder housing 304. Generally, a portion of the coil housing 306extends into the volume formed within the housing 304, while the portionof the coil housing 306 that is adapted to mate to the selector valveassembly 202 extends out of this volume. Next, a sealant material isfilled into the remaining volume within the housing 304 in order tohermetically seal the electronic components within the housing as wellas to hermetically and rigidly seal the coil housing 306 to the decoderhousing 304. The sealant material may comprise any suitable pottingmaterial, such as an epoxy, that is initially in a liquid or fluid stateand filled within the volume, and which hardens or cures with time. Inother embodiments, other suitable sealants may be applied to theinterface between the decoder housing 304 and the coil housing 306without filling the volume of the decoder housing. Advantageously, theresulting module 300 is an integrated single device in which the decodercircuitry and the coil housing are rigidly fixed to each other and forma single integrated body 302. This embodiment is easy to construct fromcommercially available components. However, it is noted that in otherembodiments, the coil housing 306 and the decoder housing 304 comprise asingle housing that is not required to be coupled or otherwisehermetically sealed to each other. One of ordinary skill in the artcould certainly design such a housing. Thus, in such embodiments, thewire coil may be directly electrically coupled to the printed circuitboard 502 and the decoder circuitry 504 within the same housing.

FIG. 6A illustrates a perspective view of the integrated coil anddecoder module 300 illustrating one embodiment of connection openings602 and 604 formed in a bottom wall 704 of the decoder housing 304. Inthis embodiment, the electrical connections 308 and 310 extend throughthe openings 602 and 604 as the decoder circuitry 504 is positionedwithin the housing 304. FIG. 6B illustrates another perspective view ofthe integrated coil and decoder module 300 illustrating a sealant orpotting material 606 filling the interior volume of housing andpreventing moisture or other contaminants from entering the housing 304at the interface between the decoder housing 304 and the coil housing306 and at the openings 602 and 604. It is noted that in otherembodiments, a single opening (as opposed to the two openings 602 and604), is formed in the decoder housing 304 that any electricalconnections extend through, while a suitable sealant or potting materialseals the opening.

Referring next to FIG. 7, a perspective view is shown of the decoderhousing 304 of the device of FIG. 3. As illustrated, in preferred formthe decoder housing 304 has an elongated rectangular parallelepipedgeometry formed by side walls 702 and a bottom wall 704. A top end ofthe housing 304 is open illustrating a volume 706 formed within and forreceiving the decoder circuitry and in some embodiments, at least aportion of the coil housing 306. It is noted that the shape of thedecoder housing 304 may take many forms other than that illustrated.

Referring next to FIG. 8, a perspective view is shown of the coilhousing 306 of the device of FIG. 3 with a partial cutaway view to showthe wire coil. The coil housing 306 includes a coil portion 802 (orsolenoid portion) and a neck portion 804. In preferred form, a portionof the neck portion 804 extends into the volume 706 formed in thedecoder housing 304. However, in other embodiments, coil housing 306does not extend into the volume but nevertheless is rigidly andsealingly coupled to the decoder housing 306. The coil portion 802 ispreferably cylindrically shaped and formed about an opening 806. Thus,the coil portion 802 has an outer cylindrical periphery and an innerconcentric cylindrical periphery. The coil portion 802 contains a wirecoil 808 or solenoid (shown in the partial cutaway view of FIG. 8)wrapping about the inner periphery and sealingly contained within thewalls of the coil portion 802. As is well known in the art, the wirecoil 808 wraps about the inner periphery in a coil shape. Upon theapplication of an electrical current through the wire coil 808, anelectromagnetic flux is formed in the opening 806 of the coil portion802 about a central axis 810 extending through the opening 806. Thisflux is used to actuate a component 812 or device (such as a plunger)typically moveable along the central axis 810 (e.g., along the path ofarrow 814) within the opening 806 of the coil portion 802 in order tocause the opening or closing of a solenoid actuated irrigation valve(e.g., in one embodiment, by opening a valve of a selector valveassembly 202 controlling the solenoid actuate irrigation valve). Inpreferred form, the component 812 does not contact the inner surfaces ofthe coil portion 802 in the opening 806 and is metallic and/or magneticin order to respond to the generated electromagnetic flux. In oneexample, the component 812 is a plunger contained within a core tube(not shown) that extends through the opening 806 and is coupled to aselector valve assembly (such as selector valve assembly 202 of FIG. 4).The plunger is held in a normally closed position within the core tubeby a spring also within the core tube. Upon the application of currentto the wire coil 808, the plunger is caused to move within the core tuberelative to the coil housing 306 (and wire coil 808) and the core tubeto open the selector valve assembly as described above. One end of thecore tube extends through the opening 806 to allow a retainer (such asretainer 214) to help hold the coil module or housing 306 in positionabout the core tube and the selector valve assembly. Such coil housings306 including the wire coil 806, as well as core tube and plungerassemblies are well-known in the art.

Referring next to FIG. 9, one embodiment is shown of a decoder-basedirrigation control system 900 including several integrated coil anddecoder modules 300 according to several embodiments of the invention.An irrigation controller 902 provides a control wire path 901 extendingfrom the controller 902 into a geographic region where irrigation isdesired. The control wire path 901 is typically buried underground. Itis understood that multiple separate control wire paths may be outputfrom the controller 902; however, for purposes of illustration, only asingle control wire path 901 is shown. Typically, the control wire path901 includes two wires, a power wire 904 and a common wire 906. A powersignal, e.g., 24 volts AC, from the controller 902 is sent on the powerline 904 to any connected devices while the common line provides areturn to complete the circuit. Generally, the power signal is ofsufficient voltage to cause a magnetic flux in the coil housing to opena solenoid activated valve 908. In other words, the electromagnetic fluxis sufficient to control irrigation equipment. In a decoder-basedsystem, the power signal is modulated or encoded with data that isreadable by the decoder circuitry as is known in the art so that thecontroller 902 can control multiple irrigation valves using the singlecontrol wire path 901.

At various locations in the field, an integrated coil and decoder module300 according to several embodiments of the invention is directlycoupled to the control wire path 901. For example, at various locationsin the field, the electrical connections 308 and 310 are coupled to thepower line 904 and the common line 906. In one embodiment, the lines andconnections are respectively coupled together using wire nuts andsilicon grease to provide water resistant electrical connections. Thedecoder portion of the integrated coil and decoder module 300 decodesthe modulated or encoded power signal on the power line 904 anddetermines whether or not to provide the power signal (electricalcurrent) to the wire coil of the integrated coil and decoder module 300(e.g., via electrical connections 506 and 508).

As described above, the wire coil generates a magnetic flux sufficientto cause device of an actuator or solenoid assembly 910 (e.g., in oneembodiment, to actuate a plunger of a selector valve assembly 202) toopen a normally closed solenoid operated valve 908 (e.g., in oneembodiment, a main control valve of a main control valve portion 206),which is coupled to a water supply line on one end and to one or moresprinkler devices on the other end. It is noted that in embodimentsimplemented in a solenoid activated rotor assembly for a pop-upsprinkler device, that a given integrated coil and decoder modulecouples to a solenoid operated valve 908 that couples to a singlesprinkler device; however, that in other embodiments, the solenoidactivate valve 908 may be coupled to multiple sprinkler devices. It isfurther noted that generally, a sprinkler device may be any rotordevice, stationary device, drip device, etc. As is known, there may bemultiple integrated coil and decoder modules 300 coupled to the controlwire path 901 at various locations. Advantageously, according to severalembodiments of the invention, by providing integrated coil and decodermodules 300 instead of separate decoder modules and coil units that mustbe coupled to each other and to the control wire path, the installationprocess has been simplified by reducing the number of wires than aninstaller must connect and by providing a more streamlined design at thecasing assembly 204. Additionally, the decoder circuitry and the coilhousing form a single rigid and integrated body.

While the invention herein disclosed has been described by means ofspecific embodiments, examples and applications thereof, numerousmodifications and variations could be made thereto by those skilled inthe art without departing from the scope of the invention set forth inthe claims.

1. An irrigation control device comprising: a body; decoder circuitrylocated within the body; a coil located within the body and coupled tothe decoder circuitry, the coil adapted to develop an electromagneticflux sufficient to cause actuation of a device controlling irrigationequipment in response to signaling from the decoder circuitry; and anelectrical connection coupled to the decoder circuitry and adapted tocouple to a control wire path of a decoder-based irrigation controlsystem, wherein the decoder circuitry and the coil are integrated into asingle device.
 2. The irrigation control device of claim 1 wherein thebody comprises: a first housing including the decoder circuitry; and asecond housing including the coil, wherein the first housing and thesecond housing are integrally coupled together.
 3. The irrigationcontrol device of claim 2 wherein a portion of the second housingextends into a volume formed within the first housing.
 4. The irrigationcontrol device of claim 2 further comprising a sealant sealing the firsthousing to the second housing.
 5. The irrigation control device of claim2 wherein the first housing defines a volume containing the decodercircuitry and a portion of the second housing, the device furthercomprising a material substantially filling the volume and sealing thedecoder circuitry and electrical connections to the second housing fromexternal moisture.
 6. The irrigation control device of claim 2 whereinthe second housing is hermetically sealed and includes a wire connectionextending from the second housing to the decoder circuitry.
 7. Theirrigation control device of claim 1 further comprising an opening inthe body and wherein the electrical connection comprises a wireextending from the decoder circuitry through the opening.
 8. Theirrigation control device of claim 1 wherein the body is watertight. 9.The irrigation control device of claim 1 further comprising a controlwire coupled between the decoder circuitry and the coil.
 10. Theirrigation control device of claim 1 wherein the decoder circuitry isadapted to control a single coil.
 11. The irrigation control device ofclaim 1 wherein the coil comprises a wire coil formed about a volume, anelectromagnetic force generated within the volume in response to theapplication of a current flowing through the wire coil.
 12. Theirrigation control device of claim 1 wherein the electrical connectioncomprises: a first wire adapted to be coupled to a power signal wire ofthe decoder-based irrigation control system; and a second wire adaptedto be coupled to a common signal wire of the decoder-based irrigationcontrol system.
 13. A method of making an irrigation control devicecomprising: providing decoder circuitry; providing a coil unitcontaining a wire coil adapted to develop an electromagnetic fluxsufficient to cause actuation of a device that causes opening andclosing of an irrigation valve upon the application of an electricalcurrent to the wire coil; coupling an output of the decoder circuitry toan input of the coil unit; inserting the decoder circuitry into ahousing such that an electrical connection to the decoder circuitry canbe made from outside of the housing; sealing the decoder circuitrywithin the housing; and sealing at least a portion of the coil unit tothe housing, whereby forming an integrated device having both thedecoder circuitry and the coil unit.
 14. The method of claim 13 whereinthe sealing the at least a portion of the coil unit comprises sealingthe at least a portion of the coil unit within the housing.
 15. Themethod of claim 13 wherein the sealing steps further comprise fillingthe housing with a sealant material.
 16. The method of claim 13 whereinthe sealing steps further comprise applying a sealant material at aninterface between the housing and the coil unit.
 17. A method ofelectrically connecting an irrigation control device to a decoder basedirrigation control system comprising: electrically coupling a firstcontrol wire of the decoder based irrigation control system to a firstelectrical connection of an integrated coil and decoder module; andelectrically coupling a second control wire of the decoder basedirrigation control system to a second electrical connection of theintegrated coil and decoder module.
 18. The method of claim 17 whereinthe integrated coil and decoder module includes decoder circuitry and awire coil integrated into a single body.
 19. The method of claim 17wherein the electrically coupling steps are performed without the needto electrically couple the decoder circuitry to a wire coil.